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Method of making and using shape memory polymer composite patches

a polymer composite and patch technology, applied in the field of repair of components, can solve the problems of composite material losing its molded shape, softening again, etc., and achieve the effect of quick and cheap permanent repair and quick and cheap joining

Active Publication Date: 2011-11-03
SPINTECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patch and process reduces the time to repair composite parts and other material and eliminates the creation of volatile components that must not be released into the environment as per EPA requirements during the repair process. The combination of both of these factors makes this process highly transferable into mass production of patches for high-performance composites at an affordable price and for the mass production of patches for use in lower performance items as well. Additionally the patch can be molded on site by hand, iteratively or in one step, without the use of significant amounts of equipment or special orders to pre-mold the composite patch to match the specific damaged area. Another benefit is that by using shape memory polymer as the resin the damaged part does not need to be removed from the larger component, for example removing the wing from the airplane, in order to mold the patch and repair the damage.
Another aspect of the invention allows the joining of two parts to create a single, larger part without the use of expensive welding, molding, or other methods that use expensive chemicals or require other controls to prevent discharge of chemicals and vapors. By placing two or more parts of similar or dissimilar shape or size in juxtaposition and using the patch to connect the parts, a larger part can be created. Once the patch is soft from activation of the shape memory polymer resin is can be molded to ensure a tight connection between two parts, even if the parts are of significant geometries. Once bonded to the individual parts, the larger part can be used.

Problems solved by technology

While some adhesives may require heat curing, choosing the correct shape memory polymer to use as the resin matrix will prevent this curing from causing the composite material to become soft again, and lose its molded shape, especially if using a light activated shape memory polymer resin.

Method used

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  • Method of making and using shape memory polymer composite patches
  • Method of making and using shape memory polymer composite patches
  • Method of making and using shape memory polymer composite patches

Examples

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examples 1 and 2

below describe the exemplary methods of creating pre-form shape memory polymer (SMP) composite parts. Example 3 below shows how to make the thermoplastic used to make the patch with thermoplastic. In general, the preferred SMP is a styrene copolymer based SMP as disclosed in U.S. Pat. No. 6,759,481, however, other types of SMPs such as cyanate ester, polyurethane, polyethylene homopolymer, styrene-butadiene, polyisoprene, copolymers of stearyl acrylate and acrylic acid or methyl acrylate, norbornene or dimethaneoctahydronapthalene homopolymers or copolymers, malemide and other materials are within the scope of the present invention.

example 1

A polymeric reaction mixture was formulated by mixing vinyl neodecanoate (10%), divinyl benzene (0.8%), and styrene (85.2%) in random order to yield a clear solution. Benzoyl peroxide paste (4%) which is 50% benzoyl peroxide, was then added to the resulting solution (all composition are by weight). The resulting solution was kept cold in a refrigerator before use. To prepare the shape memory polymer resin matrix composite sheet, a piece of 3D weave carbon fiber is placed on a glass sheet, ensuring that there are no stray fibers and the carbon fiber piece is smooth. Next, pour some of the polymeric reaction mixture onto the carbon fiber. Use a plastic squeegee or plastic spreader to spread the resin evenly over the entire surface of the fabric. Thoroughly remove air bubbles and straighten the fabric. Place bleeder and breather fabric on top of the resin soaked carbon fiber. Then place the entire system in a high temperature vacuum bag with a vacuum valve stem and apply vacuum thoroug...

example 2

A polymeric reaction mixture was formulated by mixing vinyl neodecanoate (10%), divinyl benzene (0.8%), and styrene (55.2%) in random order to form a colorless solution. Polystyrene granules (30%) were then added to the resulting solution. The resulting mixture was then allowed to sit at room temperature with occasional stirring until all the polystyrene granules were dissolved to give a clear, viscous solution. Benzoyl peroxide (4%) which is 50% benzoyl peroxide was then added to the resulting solution (all composition % are by weight). The resulting polymeric reaction mixture is continually stirred at or near 25° C., not to exceed 30° C. until a clear solution is achieved which can take 2 hours or more. The resulting solution is kept cold in a refrigerator before use. To prepare the shape memory polymer resin matrix composite sheet, a piece of 3D weave carbon fiber is placed on a glass sheet, ensuring that there are no stray fibers and the carbon fiber piece is smooth. Next, pour ...

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Abstract

A method of repairing a composite component having a damaged area including: laying a composite patch over the damaged area; activating the shape memory polymer resin to easily and quickly mold said patch to said damaged area; deactivating said shape memory polymer so that said composite patch retains the molded shape; and bonding said composite patch to said damaged part.

Description

BACKGROUND OF THE INVENTIONThe present invention generally relates to the repair of components made from material such as metals, composites, wood, plastics, glass and other materials. It is to be appreciated that the present invention has general and specific industrial application in the repair of various materials. The term “composite” is commonly used in industry to identify components produced by impregnating a fibrous material with a thermoplastic or thermosetting resin to form laminates or layers.Generally, polymers and polymer composites have the advantages of weight saving, high specific mechanical properties, and good corrosion resistance which make them indispensable materials in all areas of manufacturing. Nevertheless, manufacturing costs are sometime detrimental, since they can represent a considerable part of the total costs and are made even more costly by the inability to quickly and easily repair these material without requiring a complete, and expensive, total rep...

Claims

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Application Information

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IPC IPC(8): B32B43/00
CPCB29C35/0272B29C65/4825B29C61/003B29C61/0633B29C65/34B29C65/344B29C65/3444B29C65/3616B29C65/3636B29C65/364B29C65/3644B29C65/4835B29C65/5042B29C65/68B29C66/1142B29C66/301B29C66/43B29C66/5221B29C66/5326B29C73/10B29C2035/0811B29C2035/0827B29C65/3492B29C65/3476B29C65/5014B29C65/5021B29C65/5028B29C35/0805B29C66/7212B29C66/72143B29C66/7392B29C66/7394B29C66/72141B29C66/71B29C66/73771B29C66/73773B29C70/003B29K2307/04B29K2309/08B29K2063/00B29K2075/00B29K2033/12B29K2033/08B29K2023/18B29K2023/06B29K2009/06
Inventor HOOD, PATRICK J.
Owner SPINTECH LLC
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